Battery powered surgical instrument

ABSTRACT

A surgical stapler has a handle assembly including a stationary handle and a trigger. The stapler also has a drive assembly with a body having a working end and a cam member supported on the working end. The cam member is positioned to translate relative to the anvil to maintain the anvil in the closed position during firing of the stapler. The trigger is operatively connected to a power cell. The power cell is operably connected to a motor of the drive assembly. The manipulation of the trigger actuates the power cell such that the power cell powers the drive assembly to effect translation of the cam member relative to the anvil. The stapler also has a channel for supporting the staple cartridge and the motor of the drive assembly controls the actuation sled supported within the cartridge. The actuation sled urges the plurality of staples from the cartridge when the anvil is in the closed position and in cooperative alignment with the staple cartridge.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is a division of U.S. patent application Ser.No. 11/446,283, filed on Jun. 2, 2006, now U.S. Pat. No. 7,461,767,which claims priority to U.S. Provisional Patent Application Ser. No.60/687,406 to Viola, et al., filed Jun. 3, 2005 and to U.S. ProvisionalPatent Application Ser. No. 60/687,244 to Viola, et al., filed on Jun.3, 2005, which are herein incorporated by reference in their entirety.This application also relates to U.S. patent application Ser. No.11/446,282 to Viola, et al., filed Jun. 2, 2006, now U.S. Pat. No.7,464,847, which is herein incorporated by reference in its entirety.

BACKGROUND

1. Technical Field

The present disclosure relates to surgical instruments. Moreparticularly, the present disclosure relates to a surgical staplingdevice that has an improved and internally powered driving mechanism.

2. Background of the Related Art

Surgeons have recognized in the art the benefits of a compact surgicalapparatus for the application of surgical dips and staples to bodytissue in a number of different medical procedures. Often, prior artsurgical staplers require some degree of physical force or lateralmovement in order to operate a handle to actuate the surgical staplerand fire the staple after a compression to actuate the surgical staplerand fire the staple after a compression of tissue is made. It would bedesirable to have a precise surgical stapler device that is compact andeasy to use and will quickly and easily fire. Also, once compression ofthe desired stapling location is made, only a very limited degree offorce to the surgical stapling device should be required in order tocomplete the actuation of the device and thus firing of the staples suchas by actuating a trigger switch. Moreover, such a powered staplingdevice should be very easy to manipulate and hold by the surgeon.

Attempts have been made in the art to provide such a surgical staplingdevice that is pneumatic or gas powered and/or also externally poweredin order to remedy this desire. However, it would be beneficial toprovide a disposable apparatus for the application of staples to bodytissue that is self contained, self powered and easy to manufacture.

SUMMARY

According to a first aspect of the present disclosure, there is provideda surgical stapler. The stapler has a handle assembly including astationary handle and a trigger. The trigger is configured to manipulatea cam member through an actuating stroke. The stapler has an elongatedbody extending distally from the handle assembly and defining alongitudinal axis with a staple cartridge supported adjacent the distalend of the elongated body and containing a plurality of staples. Thestapler has an anvil pivotally mounted in relation to the cartridgeadjacent the distal end of the elongated body. The anvil has a fastenerforming surface thereon and is mounted for pivotal movement in relationto the cartridge between an open position having a distal end spacedfrom the staple cartridge and a closed position in close cooperativealignment with the staple cartridge. The stapler has an actuation sledsupported within the cartridge. The actuation sled is movable to urgethe plurality of staples from the cartridge. The stapler also has adrive assembly with a body having a working end and a cam membersupported on the working end. The cam member is positioned to translaterelative to the anvil to maintain the anvil in the closed positionduring firing of the stapler.

The trigger is operatively connected to a power cell. The power cell isoperably connected to a motor of the drive assembly. The manipulation ofthe trigger actuates the power cell such that the power cell powers thedrive assembly to effect translation of the cam member relative to theanvil. The stapler also has a channel for supporting the staplecartridge and the motor of the drive assembly controls the actuationsled supported within the cartridge. The actuation sled urges theplurality of staples from the cartridge when the anvil is in the closedposition and in cooperative alignment with the staple cartridge.

According to another aspect of the present disclosure, there is provideda surgical stapler. The stapler has a handle assembly with a stationaryhandle and a trigger configured to manipulate a cam member through anactuating stroke. The stapler also has an elongated body extendingdistally from the handle assembly and defining a longitudinal axis. Thestapler also has a staple cartridge supported adjacent the distal end ofthe elongated body and containing a plurality of staples with an anvilpivotally mounted in relation to the cartridge adjacent the distal endof the elongated body. The anvil has a fastener forming surface thereonand is mounted for pivotal movement in relation to the cartridge betweenan open position having a distal end spaced from the staple cartridgeand a closed position in close cooperative alignment with the staplecartridge.

The stapler has an actuation sled supported within the cartridge. Theactuation sled moves to urge the plurality of staples from thecartridge. The actuation sled is connected to a drive rack. The driveassembly has a body with a working end and a cam member supported on theworking end. The cam member is positioned to translate relative to theanvil to maintain the anvil in the is closed position during firing ofthe stapler.

The trigger is operatively connected to a power cell. The power cell isoperably connected to a motor of the drive assembly such thatmanipulation of the trigger actuates the power cell such that the powercell powers the drive assembly to effect translation of the cam memberrelative to the anvil. The stapler also has a channel for supporting thestaple cartridge. The motor of the drive assembly controls the actuationsled supported within the cartridge. The actuation sled urges theplurality of staples from the cartridge when the anvil is in the closedposition and in cooperative alignment with the staple cartridge.

The stapler also has a protective casing. The protecting casing housesthe power cell and the motor in the protective casing and is connectedto the stationary handle. The motor has a motor drive shaft that extendsthrough the stationary handle to connect with the drive rack.

According to another aspect of the present disclosure, the surgicalstapler is powered by an inexpensive disposable power source that may beactuated by a manual or automatic switch or switch system and that has apower cell coupled to a motor assembly to assist with actuation andfiring of the staples.

In another embodiment, the stapler has a power supply that can actuateis the stapler and the power source can easily move the drive mechanismto an appropriate position for the next stapling operation.

According to another aspect of the present disclosure, there is provideda surgical stapler. The stapler has a handle assembly including atrigger and a clamping device including a staple cartridge with aplurality of staples and an anvil having a fastener forming surfacethereon. The stapler also has a controller configured to determine anoccurrence of clamping by the anvil and the staple cartridge. Thecontroller controls firing of the plurality of staples from the staplecartridge. When the trigger is actuated the controller delays firing ofthe plurality of staples from the staple cartridge to provide for apredetermined time period of tissue compression of the tissue betweenthe anvil and staple cartridge. The controller outputs a control signalto allow firing once the predetermined time period is reached. Thestapler also has a motor having a geared assembly. The motor is disposedin the handle and configured to receive the control signal from thecontroller. The motor is operatively connected to the staple cartridgeto fire the staples from the staple cartridge once the control signal isreceived.

DESCRIPTION OF THE DRAWINGS

Other and further objects, advantages and features of the presentdisclosure will be understood by reference to the followingspecification in conjunction with the accompanying drawings, in whichlike reference characters denote like elements of structure and:

FIG. 1 is a perspective view of a first embodiment of a surgical staplerof the present disclosure;

FIG. 1A is a schematic of the handle portion of the surgical stapler ofFIG. 1 showing the trigger switch and a power cell coupled to a motor;

FIG. 2 is an exterior cross sectional view of the surgical stapler alongline 2-2 of FIG. 1 with the surgical stapler having a drive compartmentthereon;

FIG. 3 is an interior cross sectional view of the surgical stapler beingopposite the compartment;

FIG. 3A is an exploded view of a channel of the surgical stapler of oneembodiment of the stapler;

FIG. 3B is an exploded view of the staple cartridge, anvil and the drivesled of FIG. 1;

FIG. 4 is another cross sectional view of another embodiment of thesurgical stapler of FIG. 1 having a drive source in the handle of thesurgical stapler;

FIG. 4A illustrates another cross sectional view of the surgical staplerof FIG. 1 having a bevel geared arrangement;

FIG. 5 is a cross sectional view of an endoscopic portion of thesurgical stapler of FIG. 4; and

FIG. 6 is yet another cross sectional view of another embodiment of thesurgical stapler of FIG. 1 with the drive source being in the handle andgeared to the drive screw of the surgical stapler.

DETAILED DESCRIPTION

In the drawings and in the description which follows, the term“proximal”, as is traditional, will refer to the end of the apparatuswhich is closest to the operator, while the term “distal” will refer tothe end of the apparatus which is furthest from the operator.

The present disclosure shall be discussed in terms of both conventionaland endoscopic procedures and apparatus. However, use herein of termssuch as “endoscopic”, “endoscopically”, and “endoscopic portion”, amongothers, should not be construed to limit the present disclosure to anapparatus for use only in conjunction with an endoscopic tube. To thecontrary, it is believed that the apparatus of present disclosure mayfind use in procedures in these and other uses including but not limitedto where access is limited to a small incision such as arthroscopicand/or laparoscopic procedures, or any other conventional medicalprocedures known in the art.

Referring now to the figures, wherein like reference numerals identifysimilar structural elements of the subject disclosure, there isillustrated in FIG. 1 a self-contained powered surgical staplerconstructed in accordance with one embodiment of the subject disclosureand designated generally by reference numeral 10. The surgical stapler10 is a disposable surgical instrument. However, the disposablearrangement is non-limiting and other non-disposable arrangements may becontemplated and are within the scope of the present disclosure.

The surgical stapler 10 of the present disclosure shown in a perspectiveview in FIG. 1 and described herein includes a frame generallyrepresented by reference numeral 12 and handle generally represented byreference numeral 14. The frame 12 defines a series of internal chambersor spaces for supporting various mechanical components of the surgicalstapler 10 as well as a number of staples therein for the application tothe body tissue.

The frame 12 supports an endoscopic portion 16 or an extended tube-likeportion. The endoscopic portion 16 is capable of being rotated and has arelatively narrow diameter, on the order of in a range that includesabout 10 millimeters, and is for insertion into a small opening in ortube inserted into the body, such as in the abdominal cavity, or othersimilar body cavities. The endoscopic portion 16 has a longitudinal axisand has a length. The length is appropriate for reaching the operationsite in the interior of the body. The surgical stapler 10 may be used inconjunction with other instruments such as endoscopes or other suchoptical devices for visually examining the interior of the body, forexample, cameras by means of fiber optics or other optical or recordingdevices.

Generally, the endoscopic portion 16 of the surgical stapler 10 isinserted through the small opening or wound, and is manipulated to theoperation site. At the operation site, the surgical stapler 10 isactuated.

The endoscopic portion 16 has a fastening assembly 18 and cuttingassembly that is known in the art. The fastening assembly 18 and thecutting assembly are located in a housing 20 which carries a fastenerand a cutter to the operation site. The fastening assembly 18 in thisone non-limiting embodiment has a pair of jaws 21, 22, or an anvil 22and a staple cartridge 21. The jaws 21, 22 may be a first jaw 21 andsecond jaw 22 that opens and closes or alternatively another clampingstructure for compression of the tissue at the stapling site. The jaws21, 22 are defined by a staple carrying cartridge 21 and the anvil 22that is located therein. The staple carrying cartridge 21 is in oneembodiment located at the distal end of the housing 20. The staplecarrying cartridge 21 has one or a number of rows of staples. Thesurgical stapler 10 also has an anvil 22 with a forming surface (notshown) and further includes a knife (not shown) as is well known in theart for accomplishing the surgical stapling.

Generally, actuating the operating portion of the fastening assembly 18is accomplished via intermediate components disposed on or within thenarrow longitudinally extending tubular endoscopic portion 16. In oneembodiment, a cylindrical tubular sleeve member surrounds the endoscopicportion 16. The sleeve may be manipulated in a direction with thelongitudinal axis of the surgical stapling device. The surgical stapler10 of the present disclosure has three basic actions or functions.

First, the endoscopic portion 16 is introduced into the human or animalbody and is positioned with the jaws 21, 22 aligned at the desiredstapling site to receive the target tissue. This may involve rotation ofthe endoscopic portion 16 relative to the body, either by rotating thesurgical stapler 10, as a whole, by rotating simply the endoscopicportion 16 relative to the frame 12 as permitted, or a combination ofboth actions. Thereafter, the surgical stapler 10 secures the targetbody tissue between the staple cartridge 21 in the distal portion of thehousing 20 and the anvil 22. This is accomplished by a clamping actionof the jaws 21, 22 or alternatively by another similar or differentclamping member. The jaws 21, 22 are allowed to remain in the closedposition for a period of time. The jaws 21, 22 remaining closed for apredetermined period of time allow any is excess liquid or fluid in thetissues to drain out of the body tissues prior to actuation of thestapling mechanism. This ensures that the liquid does not rapidlytraverse out of the tissues to impede formation of the closed or formedstaple and ensures a proper staple formation.

With the target tissue clamped between the anvil 22 and the staplecartridge 21, a camming surface which surrounds the housing 20 and anvilmember 22 may be employed to close the jaws 21, 22 of the surgicalstapler 10 and clamp the tissue between the anvil 22 and the tissuecontacting surface of the staple cartridge 21. The jaws 21, 22 may beclamped by actuating or closing lever 24 that is opposite the jaws 21,22. Thereafter, the third action of the operator or more particularlythe surgeon is that of applying the staples to the body tissue. Alongitudinally extending channel is employed to deliver longitudinalmotion to an axial drive member and a tissue cutting knife.

The stapler 10 may have an axial drive member or an axial drive screw tocontact a pusher. The pusher elements drive the staples through the bodytissue against the fastener or forming surface of the anvil 22.Typically, in the art the surgical stapler 10 fires usually by anactuation of a first trigger 26. Thereafter, the clamping action of thejaws 21, 22 is released and the surgical stapler 10 or a portion thereofmay be withdrawn from the body cavity or site.

A known and recognized benefit is that often an operator will desire asurgical stapler 10 that is self-actuating or that actuates with only alimited degree of physical force using the trigger handle (not shown) orusing a trigger switch 26. It is envisioned that surgeons would desiresuch a surgical stapler 10 that does not have to be connected to anyexternal power supply but instead includes an internal battery operatedpower supply. Operators would desire a surgical stapler having aninternal power source that is comfortable to hold, compact and that isvery suitable for endoscopic or laparoscopic procedures as well as otherconventional surgical procedures. The stapler 10 of the presentdisclosure is advantageous since it is a compact and ergonomic member.It is also very advantageous to form such a surgical stapler 10 from fewcomponent parts relative to the prior art surgical instruments. Thisreduces manufacturing costs of the surgical stapler.

The present disclosure in one embodiment uses a motor drive sourcehaving a substantially offset or a direct drive to remedy these knownissues in the art. FIG. 1A shows a schematic illustration of an interiorof the handle 14. The surgical stapler 10 in this embodiment is poweredby a motor 30. The trigger switch 26 in this embodiment is connected bylead 27 to a power source 29 such as a battery. The battery 29 isconnected by lead 31 to a motor 30. The motor 30 is connected by lead 31to the switch 26. Upon the actuation of switch 26, power will traversefrom the battery 29 to the motor 30. The energized motor 30 will rotatethe motor drive shaft 32 to spin gear 68. Gear 68 is in contact withgear 70. Gear 68 rotates second gear 70 which will rotate drive screw66. The drive screw 66 upon rotation will move in a longitudinal mannerto actuate one or more other components of the surgical stapler 10 suchfor compression of tissue or stapling. Although, the battery 29 and themotor 30 are shown as being located in the handle 14, other locationsare contemplated.

Referring now to FIG. 2, there is shown a cross sectional view of thesurgical stapler 10 of the present disclosure along line 2-2 of FIG. 1from a rear view of the surgical stapler of FIG. 1. Disposed on anadjacent side of the surgical stapler 10 is shown a protective housing28. The protective housing 28 is for housing one or more components ofthe surgical stapler 10. The protective housing 28 may be disposed oneither adjacent side of the handle 14 or in another position beingparallel with the handle. The protective housing 28 is a generally acylindrical compact member having an interior that is disposed adjacentto, and on a lateral side of the handle 14. The protective housing 28 ismade from a suitable thermoplastic member that is suitable for surgicalprocedures and has a suitable volume to hold one or more commerciallyavailable batteries, or another power source. Although shown ascylindrical, other shapes are possible and the protective housing 28 isnot limited to this configuration. The protective housing 28 has theinterior space. The space has a compact size and has an advantageousdrive source 30 disposed therein.

The surgical stapler 10 of the present disclosure may have a first axialdrive shaft for operation of the stapling mechanism in the proximal endof the surgical stapler 10 as is known in the art. Such staplingmechanisms are well known in the art and may be found in U.S. Pat. No.6,330,965 B1 to Milliman, et al., 6,250,532 B1 to Green, et al.,6,241,139 B1 to Milliman, et al., 6,109,500 to Alli et al., 6,202,914 B1to Geiste, et al., 6,032,849 to Mastri, et al. and 5,954,259 to Viola,et al., which are all herein incorporated by reference in theirentirety.

The drive source 30 has electrical contacts to an integrated powersupply and an optional switch system. The drive source 30 is run by anyintegrated power supply that is compact, and low cost to manufacture. Inone embodiment, the drive source 30 also has a suitable amount of torquein order to fire and apply the staple to the body tissue or bone, andform the staple using a forming surface disposed on an anvil. In oneembodiment, the drive source 30 is a simple motor assembly having adrive shaft 32. The motor may be any device that converts the currentfrom the portable power cells into mechanical energy but may be anymotor that is low cost and that may be disposable and easily discardedafter use. The drive shaft 32 is connected through the handle 14 througha sealed aperture in the handle 14. Aperture may be sealed using an “O”ring or similar structure to ensure no fluids enter the stapler 10.

Alternatively, the drive source 30 may comprise any electrically poweredmotor known in the art. The present disclosure provides that the drivesource 30 may have a number of modular components that are disposable,permanent, replaceable or interchangeable. In one aspect, the motor 30may be a modular component and replaceable. In another aspect, thebattery can be a modular component and replaceable separate from thedrive source 30. In still another aspect, both the battery and the motorof the drive source 30 may be modular components. The motor and batterymay be stored in a casing or be separate units.

In one embodiment, the drive source 30 has electrical contacts to, andis powered by, one more internal power cells. The power cells may be oneor more disposable or rechargeable power cells. For example, the powercells may be a nickel cadmium type battery, an alkaline battery, alithium battery, or a nickel metal hydride and may be replaceable ordisposable with the entire surgical stapler 10. Alternatively, the powercells of the drive source 30 may also disengage from the surgicalstapler 10 for recharging. Once disconnected, the surgical stapler 10itself then may be discarded after use.

In one embodiment, the one or more power cells of the drive source 30are disposed and oriented in a generally perpendicular fashion relativeto an outer surface of the handle 14 as shown in the housing 28 andoptionally may be located in a casing with the motor assembly. In thisnon-limiting embodiment, the surgical stapler 10 may have a discreteanalog switch assembly to actuate the drive source. The switch assemblymay be located in any location or on an external surface of the surgicalstapler 10, or be integral with the trigger switch is 26. Alternatively,the drive source 30 may be actuated by a counter clockwise rotation ofthe protective housing 28 to actuate the drive source. Still further inanother embodiment, the drive source 30 may be actuated by the trigger26 or by simply the lowering an elevation of the lever 24.

Referring now to FIG. 3, there is shown an opposite lateral sidecross-sectional view of the surgical stapler 10 of FIG. 2, having thelever 24 in an elevated position or elevated and away from the handle14. The drive shaft 32 of the drive source 30 extends through thelateral side wall of the handle 14 and engages a gear assembly 34. Thegear assembly 34 may have any number of gears to transmit motion fromthe drive source 30 in protective housing 28 to another member to move asuitable driving member for stapling. The driving member is a gear rackor drive screw or other member to fire the staples in the staplecartridge 21. Various driving configuration are possible and the presentstapler 10 is not limited to any such particular driving arrangement. Inthis one non-limiting embodiment, the gear assembly 34 has a main gear36 and two subordinate gears 38, 40. The gear assembly 34 laterallyextends into the interior space of the handle 14 as shown. In oneembodiment, the gear 36 is a spur gear. In one embodiment, thesubordinate gears 38, 40 are a pair of pinion gears. In yet anotherembodiment, instead of a pair of pinion gears 38, 40, the stapler 10 mayhave one pinion gear. Various gearing configurations are possible andwithin the scope of the present disclosure.

The lever 24 as shown has a first lever side 42 that has a transverseaperture 44 being disposed therethrough. The lever 24 is connected to amember 46 by a link pin 48 through aperture 44 in the lever 24. Themember 46 moves laterally through the endoscopic portion 16. The member46 controls the jaws 21, 22 shown in FIG. 1 to open or close and for thesurgeon to clamp the jaws of the surgical stapler 10 on or at thedesired tissue site. The lever 24 also has an intermediate portion 50.The intermediate portion 50 has a second aperture 52 being disposed in abottom side of the lever 24. The lever 24 is further connected to asecond linkage assembly 54 through the second aperture 52 by a secondlink pin 56. It should be appreciated that the powered arrangement isnot limited to any such device that requires tissue approximation suchas a TA surgical stapler such as U.S. Pat. No. 6,817,508 to Racenet, etal. which is herein incorporated by reference in its entirety, and thepowered arrangement may encompass other staplers that do not require anysuch tissue approximation prior to firing.

In one embodiment, the second linkage assembly 54 has two discretelinks. Each of the links is spaced apart and is connected to one anotherto form an integral second linkage assembly 54. The second linkageassembly 54 is for translating a downward force from the lever 24 intoan axial lateral force and for moving one or more structures in thehandle 14. The second linkage assembly 54 is further fixedly connectedto an interior pin 58 of the handle 14. The lever 24 still further hasan orthogonal notch 60. The notch 60 is disposed on the lever 24 withthe notch being between the transverse aperture 44 and the secondaperture 52. The notch 60 provides clearance and prevents the lever 24from interfering or otherwise contacting the gear assembly 34 during afiring sequence or otherwise when the drive source 30 is actuated.

As shown in the raised position, the free end 62 of the lever 24 restselevated above the handle 14 as shown. As mentioned, when a staplingsite is determined by the operator, the operator will use the jaws 21,22 to compress the tissue at the stapling site to clamp the tissue for aperiod of time. The surgeon can control the jaws by lowering or closinglever 24 (from the elevated position to a position that rests on thehandle 14). Upon lowering the lever 24 from the elevated position abovethe handle 14, the lever 24 lowers the second linkage assembly 54.

The second linkage assembly 54 forces the lever 24 at the first side 42to move the member 46. The member 46 is then manipulated in a lateralaxial direction opposite the handle 14. Thus, member 46 drives the jaws21, 22 at the distal side of the surgical stapler 10 for clamping theselected body tissue between the jaws. In one embodiment, the member 46may further contact a lead, switch or mechanical member in order toprovide an audible or visual alert so as to inform thephysician/operator that a preset period of time has elapsed forcompression of tissue between the laws and the firing can begin. Variousclamp arrangements are possible and the present arrangement is forillustration purposes as it is envisioned that the clamp may be poweredby the drive source 30, or by a separate drive source.

In another embodiment of the surgical stapler 10, the surgical stapler10 may be manually actuated for stapling. In the manual embodiment, whenthe desired stapling is desired, the operator will actuate either atrigger handle (not shown) or in another embodiment will actuate ahandle assembly having a linkage. Still in another embodiment, the lever24 may operate the switch assembly at an end of the lever 24. The switchassembly 26 may be on any location of the surgical stapler 10 or may beadjacent to the protective housing 28.

The surgical stapler 10 further has a firing member 64. The firingmember 64 is laterally disposed in the handle 14 and can optionallyassist with driving an axial drive screw or another driving member toactuate the stapling mechanism in the distal side of the surgicalstapler 10. The firing member 64 may include a single driving memberthat can control both the clamping and the firing of the surgicalstapler 10. In another embodiment, the firing member 64 canalternatively include separate driving members with one driving memberfor the firing of the stapler cartridge 21 and another driving memberfor closing the jaws 21, 22. Various configurations are possible andwithin the scope of the present disclosure. The firing member 64 is alongitudinal member having a bottom driving surface 65. However, thelongitudinal firing member 64 can be a single component or constructedof other multiple members. The firing member 64 is disposed in alongitudinal manner in the interior of the handle 14 of the surgicalstapler 10. Upon actuation, the motor in the housing 28 spins the maingear 36 that contacts or is connected to the bottom driving surface 65of the firing member 64. Gear 36 rotates in a counterclockwise fashion.Thus, in this manner, the drive source 30 will rotate the gear assembly34 that will move the firing member 64 in an axial direction toward thedistal direction of the surgical device 10 and away from the handle 14.A rotation of the main gear 36 applies a force to the firing member 64on the bottom driving surface 65 for the purpose of axially moving thefiring member in a longitudinal distal manner. This axial movement ofthe firing member 64 will impart an axial force the corresponding memberin the endoscopic potion 16 that will engage the stapling mechanism.

A beneficial aspect of the present disclosure is that the drive source30 will then allow a greater amount of torque to be applied to thedriving member 64 relative to a manually actuated apparatus without anymotor assembly 30. A significant aspect of the present disclosure isthat the drive source or motor 30 is a low cost device that may bediscarded. Given that the drive source 30 may be discarded, the drivesource or motor 30 may be connected to an optional analog or digitalcircuit on a controller to drive the firing member 64 with apredetermined amount of torque so that a considerable amount of power isreleased from the drive source 30 each instance the firing is desired.Moreover, the surgical stapler 10 provides that the firing member 64 isdirectly driven by the drive source 30, or geared by a number of gearsfor the purpose of actuating the stapling mechanism without undue forceor movement applied to the handle 14 or another trigger handle (notshown) of the surgical stapler 10. This is advantageous since thesurgeon can precisely locate the stapler 10 at a site and then fire thestapler 10

FIG. 3A shows an exploded view of a number of components of the surgicalstapler 10 of FIG. 1. The stapler 10 has a rack 64 that is slidable inthe handle portion 14. The rack 64 interfaces with a clamp tube 102. Ona distal side of the clamp tube 102 is a channel 104. The channel 104engages with the clamp tube 102 and a pair of forks 106, 108 on a distalside thereof. The stapler 10 also has an upper cover 110 and a lowercover 112, and an extension tube 114. The extension tube 114 engageswith a collar tube 116. The stapler 10 also has a rotation knob 118 witha channel portion 120. The channel portion 120 has a pair of cammingsurfaces 122 on a distal end. The distal end also has a crimp 124 in adistal side to receive the anvil 22.

In operation, the rack 64 slides and moves the clamp tube 102 distally.The clamp tube 102 is provided to interconnect the handle portion 14 andthe extension tube 114. The channel 104 is slidably mounted forreciprocal longitudinal motion. The extension tube 114 provides supportfor the surgical stapler 10 and has slots that interface with the collartube 116. The surgical stapler 10 also has a support 120 forlongitudinal motion and to operate the stapling mechanism as describedin FIG. 2 b. The operation of these components is well known and isdisclosed in U.S. Pat. No. 5,318,221 to Green, et al., which is hereinincorporated by reference in its entirety.

Advantageously, the rack 64 is driven distally to advance the channel104 in a distal manner. The channel 104 delivers longitudinal motion toa pusher cam bar or an axial drive member as is known in the art foroperation of the staple cartridge 21 shown in FIG. 2 b. It should beappreciated that the components shown in FIG. 3A only illustrate oneembodiment of the present surgical stapler 10, and instead of the rack64, the surgical stapler 10 may have a drive screw (FIG. 4) forlongitudinal motion and in order to actuate the staple cartridge 21.Referring now to FIG. 3B, there is shown an exploded view of the anvil22 and the staple cartridge 132 having an actuation sled 169.

Referring to FIG. 2 b, the staple cartridge 21 includes an anvilassembly 130 and a cartridge assembly 132 shown in an exploded view forillustration purposes. The anvil assembly 130 includes anvil portion 22having a plurality of staple deforming concavities (not shown) and acover plate 136 secured to a top surface of anvil portion 134 to definea cavity (not shown). The cover plate 136 prevents pinching of tissueduring clamping and firing of the surgical stapler 10. The cavity isdimensioned to receive a distal end of an axial drive assembly 138.

The anvil 130 has a longitudinal slot 140 that extends through anvilportion 130 to facilitate passage of retention flange 142 of the axialdrive assembly 138 into the anvil slot 140. A camming surface 144 formedon anvil portion 22 is positioned to engage axial drive assembly 138 tofacilitate clamping of tissue. A pair of pivot members 146 formed onanvil portion 130 is positioned within slots 146′ formed in carrier 148to guide the anvil portion 130 between the open and clamped positions.

The stapler 10 has a pair of stabilizing members 152 engage a respectiveshoulder formed on carrier 148 to prevent anvil portion 130 from slidingaxially relative to staple cartridge 132 as camming surface of the anvil130 is deformed. Cartridge assembly 132 includes the carrier 148 whichdefines an elongated support channel 154. Elongated support channel 154is dimensioned and configured to receive the staple cartridge 132 whichis shown above the carrier 148 in the exploded view of FIG. 2 b.Corresponding tabs and slots formed along staple cartridge 132 andelongated support channel 148′ function to retain staple cartridge 132within support channel 154 of carrier 148. A pair of support strutsformed on the staple cartridge 132 are positioned to rest on side wallsof carrier 148 to further stabilize staple cartridge 132 within supportchannel 154, however other arrangements to support the cartridge 132 onthe channel 154 can be used and this arrangement is not limiting.

Staple cartridge 132 includes retention slots 156 for receiving aplurality of fasteners 158 and pushers 160. Longitudinal slots 156extend through staple cartridge 132 to accommodate upstanding cam wedges162 of the actuation sled 164. A central longitudinal slot 166 extendsalong the length of staple cartridge 132 to facilitate passage of aknife blade (not shown). During operation of surgical stapler 10,actuation sled 164 is drive distally to translate through longitudinalslot 156 of staple cartridge 132 and to advance cam wedges 162 distallyand into sequential contact with pushers 160, to cause pushers 160 totranslate vertically within slots 156 and urge fasteners 158 from slots156 into the staple deforming cavities of anvil assembly 130 to effectthe stapling of tissue.

Referring now to FIG. 4, there is shown another embodiment of thepresent disclosure. In this embodiment, the drive source 30 is disposedin an interior space of the handle 14 in a location to balance anoverall weight of the surgical stapler 10 for a more ergonomic,comfortable design. The surgical stapler 10, in this embodiment, has adrive screw 66 as a drive member in contrast to the rack 64 of FIG. 3A.The drive screw 66 is a threaded rod having a number of helical groovesthat are intended to rotate and contact another axial member shown aboveto actuate the stapling mechanism in the distal location of the surgicalstapler 10 once a tissue compression is made by the surgeon. Variousconfigurations are possible, and it should be appreciated that thestapler 10 of the present disclosure is not intended to be limited toany specific stapler mechanism.

In one embodiment, the drive source 30 is disposed and lies in alongitudinal plane in the handle 14. The drive source 30 is disposedsubstantially parallel to a longitudinal axis of the surgical stapler10. This location of the drive source 30 provides for a compact and selfpowered surgical stapler 10 that may be comfortably balanced andergonomically grasped by the surgeon. The drive source 30 has the driveshaft 32. Drive shaft 32 is connected to a first drive gear 68. Thefirst drive gear 68 has teeth that mesh with, and rotate a number ofteeth of a second translating gear 70 as shown.

The second translating gear 70 further has a bore or aperture in acenter of the second translating gear 70. The second translating gear 70further is connected to a collar 72 in a center of the secondtranslating gear. The collar 72 engages the drive screw 66 of thesurgical stapler 10. A clockwise rotation of the second translating gear70 will also rotate the collar 72 in a similar direction. The collar 72will then, upon rotation, cooperates and engage with the drive screw 66to move the drive screw 66 in a distal manner.

This rotation of the collar 72 allows the drive screw 66 to rotate andmove distally. The drive screw 66 rotates and moves in an axial mannerthrough the bore of the second translating gear 70 and the collar in adirection toward and through the endoscopic portion 16 of the surgicalstapler 10. Upon rotation, the drive screw 66 will traverse laterally byrotation into the endoscopic portion 16 a predetermined amount in adirection away from the handle 14 of the surgical stapler 10 to actuatethe stapler mechanism. A significant aspect of this embodiment is thatthe drive screw 66 has a considerable amount of torque from motor 30 inorder to translate the force to the staple mechanism and to form thestaples against anvil.

FIG. 4A illustrates another embodiment of the surgical stapler 10. Inthis embodiment, the motor 30 is shown unconnected from any power supplyfor illustration purposes. The motor 30 has a drive shaft 32. The driveshaft 32 is connected to a first bevel gear 31.

In this embodiment, the motor 30 is disposed at ninety degrees from thedrive screw 66. Upon the actuation of trigger switch 26 (FIG. 1) powerwill traverse from the battery 29 to the motor 30 (FIG. 1A). Theenergized motor 30 will rotate the motor drive shaft 32 to spin bevelgear 31. Bevel gear 31 is in contact with second gear 33 that isdisposed in concentric fashion with drive screw 66 using member 72 asdiscussed above.

Bevel gear 31 will rotate drive screw 66 to move the drive screw 66 in alongitudinal manner to actuate one or more other components of thesurgical stapler 10 such for tissue compression or for stapling. Bevelgear 31 is useful to change a rotation direction of the motor outputshaft 32 to move drive screw 66 longitudinally or distally andproximally, and to orient the motor 30 in an advantageous mannerrelative to the handle 14. Bevel gear 31 has teeth that can be straight,spiral or hypoid. Although bevel gear 31 is shown as perpendicular togear 33, other arrangements are contemplated. Instead, of bevel gear 31with second gear 33 oriented as shown the surgical stapler 10 mayincorporate a hypoid gear which can engage with the axes in differentplanes. Hypoid gear may further permit different spacing arrangements ofthe motor 30 relative to the drive screw 66 to further provide for amore compact, balanced and ergonomic stapler design.

Referring now to FIG. 5, there is shown a cross sectional view of theendoscopic device 16. Upon actuation, the drive screw 66 rotates apredetermined distance through a central bore 74 in the endoscopicportion 16. After traversing the predetermined distance, the drive screw66 will contact a longitudinal firing member 76. The longitudinal firingmember 76 will then contact a complementary structure to fire thestaples in the staple cartridge 21 in the distal region of the surgicalstapler 10 as is known in the art. In another exemplary embodiment, ofthe present disclosure, the drive source 30 may be a reversible drivesource. Additionally, the staple cartridge 21 may have one row ormultiple rows of staples and the surgical stapler 10 may fire with anamount of torque to easily form staples having the desiredconfiguration.

In this alternative embodiment, the drive screw 66 may reverseautomatically or manually to move proximally at the conclusion of thestapling relative to the endoscopic portion 16. Upon the drive source 30actuated by the switch 26 or another manual or automatic actuatingdevice, the drive source rotates the drive shaft 32 in the oppositerotational direction. The drive shaft 32 then rotates the first drivegear 68 in the opposite rotational direction. Thereafter, a number ofteeth of the first drive gear 66 rotate the second translating gear 70in the opposite direction. The second translating gear 70 will thenrotate the drive screw 66 in the opposite direction to return the drivescrew 68 to an initial position for the next stapling operation.

Referring now to FIG. 6, there is shown another alternative embodimentof the present disclosure. In this embodiment, the jaws 21, 22 arepowered by the drive source 30. The jaws 21, 22 may be moved in closealignment with one another to clamp tissue therebetween and be poweredby motor or drive source 30. The surgical stapler 10 has a drive source30 that has a drive gear 74 being connected to the output drive shaft(not shown) of the motor 30 or drive source. The drive gear 74 isdirectly connected to the drive source 30, however alternatively may beconnected to the drive source 30 by another gear or by another linkagedepending on the space constraints of the handle 14. The surgicalstapler 10 further has a second translation gear 76. The secondtranslation gear 76 also is connected through the drive screw 66 thatdrives the drive screw 66 to fire the staple cartridge 21 as discussedpreviously.

In this embodiment, the lever 24 is connected to the linkage assembly 54at the intermediate portion 50 of the lever 24. The lever 24 whenlowered from the elevated position, imparts a downward force on thelinkage assembly 54. Thereafter, the linkage assembly 54 fixed at oneend by the interior pin 58 rotates about the interior pin and moves thelever 24 in an axial manner. This moves and advances a linkage (notshown) for clamping the tissue. Still further, the member or anothercomponent may actuate a timer (not shown) or display to alert thephysician/operator to activate the trigger and to initiate the drivesource 30. In still another embodiment of the present disclosure, theclamping may be mechanically connected or linked to the drive source 30to provide for a powered compression of tissue. In still anotherembodiment, the clamping can be performed simultaneously with the firingof the trigger handle 26, and may be powered by the drive source 30 asopposed to independently of firing.

Once the actuation of the drive source 30 occurs, the drive source willturn the drive gear 74. The drive gear 74 will then directly rotate thesecond translation gear 76 and the drive screw 66 disposed directlythrough the bore of the second translation gear. Again, the drive screw66 will then impart the required axial force to discharge the staplesfrom the staple cartridge 21 in the distal location of the surgicalstapler 10. As mentioned, once the drive screw 66 travels apredetermined distance, the drive screw 66 will actuate thecorresponding stapler mechanism to fire the staples in the staplecartridge 21.

Although shown as an endoscopic surgical stapler, the present drivesystem may be used with any surgical stapling device known in the art,such as endoscopic surgical stapling devices, a multi-fire GIA surgicalstapler, a TA surgical stapling device, and/or any other surgicalstapler device known in the art The present instrument may also be usedwith a single drive surgical stapler that drives both the clampingdevice of the jaws 21, 22 and the stapling device.

It should be understood that the foregoing description is onlyillustrative of the present disclosure. Various alternatives andmodifications can be devised by those skilled in the art withoutdeparting from the disclosure. Accordingly, the present disclosure isintended to embrace all such alternatives, modifications and variances.The embodiments described with reference to the attached drawing figuresare presented only to demonstrate certain examples of the disclosure.Other elements, steps, methods and techniques that are insubstantiallydifferent from those described above and/or in the appended claims arealso intended to be within the scope of the disclosure.

1. A surgical stapler comprising: a) a handle assembly including astationary handle and a trigger configured to manipulate a cam memberthrough an actuating stroke; b) an elongated body extending distallyfrom the handle assembly and defining a longitudinal axis; c) a staplecartridge supported adjacent the distal end of the elongated body andcontaining a plurality of staples; d) an anvil pivotally mounted inrelation to the cartridge adjacent the distal end of the elongated body,the anvil having a fastener forming surface thereon and being mountedfor pivotal movement in relation to the cartridge between an openposition having a distal end spaced from the staple cartridge and aclosed position in close cooperative alignment with the staplecartridge; e) an actuation sled supported within the cartridge, theactuation sled being moveable to urge the plurality of staples from thecartridge; f) a drive assembly including a body having a working end anda cam member supported on the working end, the cam member beingpositioned to translate relative to the anvil to maintain the anvil inthe closed position during firing of the stapler; g) wherein the triggeris operatively connected to a power cell, the cell being operablyconnected to a motor of the drive assembly such that manipulation of thetrigger actuates the power cell such that the power cell powers thedrive assembly to effect translation of the cam member relative to theanvil; h) a channel for supporting the staple cartridge; i) the motor ofthe drive assembly controlling the actuation sled supported within thecartridge, wherein the actuation sled urges the plurality of staplesfrom the cartridge when the anvil is in the closed position and incooperative alignment with the staple cartridge; and j) a protectivehousing connected to an outside surface of the stationary handle, themotor of the drive assembly and the power cell disposed in theprotective housing, the protective housing is releasably coupled to theassembled stationary handle of the stapler.
 2. The stapler of claim 1,wherein the power cell is a nickel cadmium battery.
 3. The stapler ofclaim 1, wherein the power cell is an alkaline battery.
 4. The staplerof claim 1, wherein the power cell is a lithium battery.
 5. The staplerof claim 1, wherein the power cell is a nickel metal hydride battery. 6.The stapler of claim 1, wherein the power cell is disposable with thesurgical stapler.
 7. The stapler of claim 1, wherein the power cell isreplaceable from the surgical stapler.
 8. The surgical stapler of claim1, wherein the motor of the drive assembly and the power source are bothin the protective housing.
 9. The surgical stapler of claim 1, whereinthe drive assembly comprises a motor having a motor drive shaft, themotor drive shaft being connected to a first gear; wherein the driveassembly further comprises a second gear being connected to theactuation sled, wherein upon actuation the motor drives the motor driveshaft to spin the first gear, the first gear being in contact with thesecond gear, wherein upon rotation of the first gear, the first gearrotates the second gear to rotate a second drive shaft, the second driveshaft moving the actuation sled to urge the plurality of staples fromthe cartridge.
 10. The stapler of claim 9, wherein the second driveshaft is a drive screw.
 11. The surgical stapler of claim 1, wherein thedrive assembly comprises a motor having a motor drive shaft, the motordrive being connected to a first gear; wherein the drive assemblyfurther comprises a rack being connected to the actuation sled, whereinupon actuation the motor drives the motor drive shaft to spin the firstgear, the first gear being in contact with the rack, wherein uponrotation of the first gear, the first gear rotates and moves the rackdistally, the rack moving the actuation sled distally to urge theplurality of staples from the cartridge.
 12. The surgical stapler ofclaim 11, wherein the motor is disposed outside of the stationary handlein the protective housing.
 13. The surgical stapler of claim 12, whereinthe motor drive shaft extends through the stationary handle.
 14. Thesurgical stapler of claim 13, wherein the power cell is in theprotective housing.
 15. The surgical stapler of claim 12, wherein themotor is reversible, and wherein upon reverse actuation the motor drivesthe motor drive shaft to spin the first gear in an opposite direction,the first gear being in contact with the rack, wherein upon rotation ofthe first gear in the opposite directions, the first gear rotates andmoves the rack proximally, the rack moving the actuation sled proximallyto return the actuation sled to an initial position.
 16. The surgicalstapler of claim 15, wherein the motor automatically spins the firstgear in an opposite direction after the plurality of staples are urgedfrom the staple cartridge.
 17. The surgical stapler of claim 1, whereinthe drive assembly comprises a motor having a motor drive shaft, themotor drive shaft being connected to a first gear; wherein the driveassembly further comprises a second gear being connected to a drivescrew, wherein upon actuation the motor drives the motor drive shaft tospin the first gear, the first gear being in contact with the secondgear, wherein upon rotation of the first gear, the first gear rotatesthe second gear to rotate the drive screw, the drive screw moving theactuation sled to urge the plurality of staples from the cartridge. 18.A surgical stapler comprising: a) a handle assembly including astationary handle and a trigger configured to manipulate a cam memberthrough an actuating stroke; b) an elongated body extending distallyfrom the handle assembly and defining a longitudinal axis; c) a staplecartridge supported adjacent the distal end of the elongated body andcontaining a plurality of staples; d) an anvil pivotally mounted inrelation to the cartridge adjacent the distal end of the elongated body,the anvil having a fastener forming surface thereon and being mountedfor pivotal movement in relation to the cartridge between an openposition having a distal end spaced from the staple cartridge and aclosed position in close cooperation alignment with the staplecartridge; e) an actuation sled supported within the cartridge, theactuation sled being moveable to urge the plurality of staples from thecartridge; f) a drive assembly including a body having a working end anda cam member supported on the working end, the cam member beingpositioned to translate relative to the anvil to maintain the anvil inthe closed position during firing of the stapler; g) wherein the triggeris operatively connected to a power cell, the cell being operablyconnected to a motor of the drive assembly such that manipulation of thetrigger actuates the power cell such that the power cell powers thedrive assembly to effect translation of the cam member relative to theanvil; h) a channel for supporting the staple cartridge; i) the motor ofthe drive assembly controlling the actuation sled supported within thecartridge, wherein the actuation sled urges the plurality of staplesfrom the cartridge when the anvil is in the closed position and incooperative alignment with the staple cartridge; j) a protective casing,the protective casing housing the power cell and the motor, theprotective casing being connected to the stationary handle, wherein themotor has a motor drive shaft that extends through the stationary handleto connect with the drive rack; and k) wherein the protective casinghousing the power cell and the motor is releasably coupled to thestapler and wherein at least one of the power cell and the motor isreleasably coupled to the protective casing.
 19. The stapler of claim18, wherein the power cell is selected from the group consisting of anickel cadmium battery, an alkaline battery, a lithium battery, a nickelmetal hydride battery, and any combination thereof.
 20. The stapler ofclaim 18, wherein the power cell is disposable with the surgicalstapler.
 21. The stapler of claim 18, wherein the power cell isreplaceable from the protective housing.
 22. The surgical stapler ofclaim 18, wherein the motor is reversible, and wherein upon reverseactuation the motor drives the motor drive shaft to move the rack in anopposite direction, wherein the rack moves the actuation sled proximallyto return the actuation sled to an initial position.
 23. The surgicalstapler of claim 18, wherein the motor drive shaft is connected to agear, the gear contacting the drive shaft to move the drive shaftdistally.
 24. The surgical stapler of claim 18, wherein the protectivehousing is releasably attached to an outer surface of the stationaryhandle.